Compost system with error detection

ABSTRACT

A controller for a compost system comprises a plurality of control outputs in communication with a plurality of compost devices. The control outputs are configured to identify an error condition of at least one of the plurality of compost devices. The controller is configured to control a first compost device configured to control a first environmental condition and control a second compost device configured to control a second environmental condition of a compost chamber. The controller is further configured to deactivate the first compost device in response to an error condition during a compost cycle. The controller controls the second compost device in response to the first compost device being deactivated preserving the compost cycle by compensating for the error condition in the first compost device.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No.14/310,045, entitled “COMPOST SYSTEM WITH ERROR DETECTION,” filed onJun. 20, 2014. The entire disclosure of the application is herebyincorporated by reference.

BACKGROUND

The present disclosure relates generally to a compost system and moreparticularly relates to a controller for a compost system.

SUMMARY

In one aspect of the present disclosure a controller for a compostsystem is disclosed. The controller comprises a plurality of controloutputs in communication with a plurality of compost devices. Thecontrol outputs are configured to identify an error condition of atleast one of the plurality of compost devices. The controller isconfigured to control a first compost device of the plurality of compostdevices configured to control a first environmental condition of acompost chamber and control a second compost device of the plurality ofcompost devices configured to control a second environmental conditionof the compost chamber. The controller is further configured to identifythe error condition of the first compost device and deactivate the firstcompost device in response to the error condition during a compostcycle. The controller controls the second compost device in response tothe first compost device being deactivated preserving the compost cycleby compensating for the error condition in the first compost device.

In another aspect of the present disclosure, a method for controlling acompost system is disclosed. The method comprises selectively actuatinga first compost device of the compost system. The first compost deviceis configured to control a first environmental condition of a compostchamber. The method further comprises selectively actuating a secondcompost device of the compost system. The second compost device isconfigured to control a second environmental condition of the compostchamber. The method further comprises monitoring the operation of thefirst compost device and detecting an error condition in the firstcompost device. In response to the error condition, the operation of thefirst compost device is limited. In response to the limited operation ofthe first compost device, the second compost device is controlledpreserving the compost cycle by compensating for the error condition inthe first compost device.

These and other features, advantages, and objects of the present devicewill be further understood and appreciated by those skilled in the artupon studying the following specification, claims, and appendeddrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block diagram of a compost system utilizing a controllerconfigured to identify and control errors in the compost system;

FIG. 2 is a block diagram of a controller configured to identify andcontrol errors in a compost system;

FIG. 3 is a schematic diagram of a control circuit configured toselectively activate a current sensing function;

FIG. 4 is a flow chart demonstrating a method for controlling a compostsystem; and

FIG. 5 is a flow chart demonstrating a method for controlling a compostsystem in accordance with the disclosure.

DETAILED DESCRIPTION OF EMBODIMENTS

The detailed description set forth below is intended as a description ofvarious configurations of the subject technology and is not intended torepresent the only configurations in which the subject technology may bepracticed. The appended drawings are incorporated herein and constitutea part of the detailed description. The detailed description includesspecific details for the purpose of providing a thorough understandingof the subject technology. However, it will be clear and apparent tothose skilled in the art that the subject technology is not limited tothe specific details set forth herein and may be practiced using one ormore implementations. In one or more instances, well-known structuresand components are shown in block diagram form in order to avoidobscuring the concepts of the subject technology.

Referring to FIGS. 1 and 2, a compost system 10 is shown demonstrating acontroller 12 configured to identify and control errors in the compostsystem 10. The controller 12 comprises at least one control output, forexample, one of a plurality of control outputs O1, O2, O3, O4, and O5.The controller 12 comprises one or more circuits (e.g. load sensingcircuits) configured to monitor the load current conditions for each ofthe control outputs O1-O5. A load current of each of the control outputsO1-O5 may be monitored by the controller 12 to determine abnormal loadcurrent conditions for each of the control outputs O1-O5.

The at least one control output is in communication with a compostdevice 18. The compost device 18 may correspond to any device configuredto control an operation, a process, and/or an environmental condition ofthe compost system 10. In some implementations, the compost device 18may comprise a water supply device 20, a tiller motor 22, a heater 24, afan 26, a feeder 28, a bin transfer device, and various devices that maybe utilized in, or implemented in combination with, the compost system10. The compost device 18 is configured to control an environmentalcondition of a compost chamber 34 of the compost system 10.

The controller 12 is operable to monitor the load sensing circuits andgenerate a load value to quantify the load current. With the load value,the controller 12 is operable to compare the load value to at least onepredetermined value or current threshold value to determine an errorcondition of the compost system 10. The various methods and systemsdisclosed herein provide for enhanced operation of compost systems byidentifying and controlling error conditions to prevent damage to thecompost system 10 and the compost devices 18.

In some embodiments, the controller 12 is operable to maintain anoperation of one or more compost devices even after an error conditionhas been identified by the controller 12. An error condition maycomprise any state of operation of at least one composting deviceoutside of normal operating parameters. For example, an error conditionmay include a blockage, a breakage, a malfunction, an over orunder-current condition, an overheating condition, or any othercondition outside of normal operation of the compost devices 18. Bymaintaining safe operation of the compost system 10 and the compostdevices 18 after an error condition has been detected, this disclosureprovides for systems and methods operable to continue production ofcompost, even after one or more input devices is identified asmalfunctioning.

Referring again to FIG. 1, the compost chamber 34 includes a first bin36 and a second bin 38. During processing of biodegradable refuse,refuse materials, or compost materials, the compost system 10 utilizesthe first bin 36 to process and condition the refuse to ensure that therefuse materials are efficiently decomposed to generate compost.Processing and conditioning the refuse material may include addingwater, controlling airflow, tilling, heating, adding coir pellets, andany other processes that may be utilized in a composting system. Thecontroller 12 is operable to control the environmental conditions withinthe first bin 36 during various stages of decomposition of the refusebased on one or more settings and/or algorithms programmed in a memoryof the controller 12. Once the refuse materials are decomposed andcompost is formed, the controller 12 is operable to open a transfer door40 to transfer the compost from the first bin 36 to the second bin 38.

The controller 12 is configured to monitor the refuse material in thefirst bin 36 via a plurality of signal inputs I1-I5. The signal inputsI1-I5 may comprise various forms of inputs configured to receive signalsfrom one or more sensors or transducers. In some embodiments, the signalinputs I1-I5 may be implemented as digital inputs or analog inputs incommunication with at least one analog to digital (A/D) converter thatmay be incorporated in the controller 12. Each of the plurality ofsignal inputs I1-I5 is in communication with a transducer S1-S5configured to monitor an environmental condition of the compost chamber34.

In an exemplary embodiment, the first signal input I1 is incommunication with a first transducer S1, the second signal input I2 isin communication with a second transducer S2, and the third signal inputI3 is in communication with a third transducer S3. Each of the signalinputs I1-I5 is configured to receive signals corresponding to theenvironmental conditions of the compost chamber 34 from the transducersS1-S5. Though the implementation demonstrated in FIG. 1 illustrates fivesignal inputs I1-I5 corresponding to five transducers S1-S5, thecontroller 12 may be configured to incorporate any number of signalinputs corresponding to any number of transducers utilized in aparticular compost system.

The transducers S1-S5 may be configured to monitor a variety ofenvironmental conditions corresponding to the compost chamber 34. Forexample, environmental conditions may include a humidity level, anoxygen level, and a temperature within the compost chamber 34, as wellas any other environmental condition that may be monitored in thecompost system 10. In an exemplary implementation, the first transducerS1 is an oxygen sensor, the second transducer S2 is a humidity sensor,and the third transducer S3 is a temperature sensor. Each of thetransducers S1-S5 discussed herein may be implemented by a variety ofsensors. For example, the oxygen sensor may be a zirconia oxygen sensor,the humidity sensor may be a resistive or capacitive humidity sensor,and the temperature sensor may be a resistive or infrared temperaturesensor. Though particular transducers are described herein, a variety ofsensor types may be utilized without departing from the spirit of thedisclosure.

In response to the environmental conditions determined from the signalsreceived by the signal inputs I1-I5, the controller 12 may adjust theenvironmental conditions of the compost chamber 34 by controlling aplurality of compost devices 18. Each of the control outputs O1-O5 isconfigured to control a compost device 18. The control outputs O1-O5 areconfigured as follows:

the first control output O1 is configured to control the water supplydevice 20;

the second control output O2 is configured to control the tiller motor22;

the third control output O3 is configured to control the heater 24;

the fourth control output O4 is configured to control the fan 26; and

the fifth control output O5 is configured to control the feeder 28.

Though the implementation demonstrated in FIG. 1 illustrates fivecontrol outputs O1-O5 corresponding to five compost devices 18, thecontroller 12 may be configured to incorporate any number of controloutputs corresponding to compost devices utilized in a particularcompost system.

The water supply device 20 may be implemented as a water pump or a watercontrol valve configured to control water supplied to the compostchamber 34 from a water supply 42. The water supply device 20, as wellas the tiller motor 22, the fan 26, and the feeder 28, may utilizeelectric motors. The electric motors may be of any form, and in someimplementations may be stepper motors, servomotors, alternating current(AC) motors and/or direct current (DC) motors. Depending on a particularelectric motor implemented for each of the compost devices 20, 22, 24,26, 28, the corresponding output controls O1, O2, O3, O4, and O5 may beconfigured to control the particular electric motor corresponding to aparticular compost device 18.

The tiller motor 22 is coupled to a tiller bar 44 and is operable torotate the tiller bar 44 to aerate the refuse material in the first bin36 of the compost chamber 34. The heater 24 is positioned within thecompost chamber 34 and operable to supply heat to the refuse material.The heater 24 may comprise electrically resistive elements configured toheat the refuse material in response to current supplied by thecontroller 12. The fan 26 is in fluid communication with an oxygenatedair source and is configured to move compost odors through a filtersystem and supply air into the compost chamber 34. The feeder 28 isoperable to supply composting of coir pellets into the compost chamber34 by actuating an agitator to selectively feed a desired number of coirpellets into the compost chamber 34. Via the control outputs O1-O5, thecontroller 12 is operable to selectively activate and deactivate each ofthe compost devices 18 to adjust the environmental conditions within thecompost chamber 34.

In an exemplary embodiment, the controller 12 is configured to monitorthe load current drawn by each of the compost devices 18 including theload current drawn by the water supply device 20, the load current drawnby the tiller motor 22, the load current drawn by the heater 24, theload current drawn by the fan 26, and the load current drawn by thefeeder 28. During operation of each of the compost devices 18, thecontroller 12 is configured to measure at least one current drawn by thecompost devices 18 and generate a load value. The load value is comparedby the controller 12 to a first current threshold and a second currentthreshold to ensure that each of the compost devices 18 is operatingproperly.

Each of the compost devices 18 may have different operating parametersexpected during normal operation. Accordingly, based on the operatingparameters of each of the compost devices 18, a first current thresholdand a second current threshold may be stored in a memory of thecontroller 12. The first and second current thresholds may correspond topredetermined values corresponding to normal and safe operatingparameters of each of the compost devices 18. The controller 12 isconfigured to store a specific first current threshold and a specificsecond current threshold corresponding to each of the compost devices 18for comparison to load values measured by the controller 12 to detect anerror condition.

The first current threshold may correspond to a minimum normal operatingcurrent and the second current threshold may correspond to a maximumnormal operating current corresponding to each of the compost devices18. The controller 12 is configured to store the current thresholds foreach of the compost devices 18 as load current profiles. The loadcurrent profile for a specific compost device (e.g. the heater 24) maybe accessed by the controller 12 to compare the current load of thecompost device to the normal operating parameters. In this way, thecontroller is operable to detect an error condition for each of thecompost devices 18 while controlling the compost system 10.

The following example illustrates a detection of an error conditionidentified by the controller 12. In response to the first transducer S1(e.g., the oxygen sensor) communicating to the controller that theoxygen level in the compost chamber 34 is below a desired level, thecontroller 12 is configured to activate one or more of the controloutputs O1-O5 to increase the oxygen level. The controller 12 mayactivate the fan 26 via the fourth control output O4 and the tillermotor 22 via the second control output O2. During operation of the fan26 and the tiller motor 22, the controller 12 may monitor the loadcurrent drawn by the fourth output O4 corresponding to the fan 26 andthe second output O2 corresponding to the tiller motor 22. By monitoringthe current of the active compost devices 18, the controller 12 isconfigured to determine the electrical current or load current drawn bythe fan 26 and the tiller motor 22.

The controller 12 is further operable to generate a load value toquantify each of the load currents measured from the fourth output O4and the second output O2. If the load value determined for the fourthoutput O4 is less than a first fan current threshold or greater than asecond fan current threshold based as determined from the currentprofile for the fan 26, the controller 12 is configured to identify anerror condition for the fan 26. If the load value is less than the firstfan current threshold, the controller 12 is operable to determine thatthe fan 26 is in a non-operational condition. For example, the fan motormay be damaged such that there is a smaller load current draw than isrequired for operation of the fan 26. If the load value is greater thanthe second fan current threshold, the controller 12 is operable todetermine that the fan motor is operating in an over-current condition.The over-current condition may correspond to a fan blade blocked byforeign material, an overheating condition that may correspond toinefficient operation, or a variety of additional error states for thefan motor, and consequently, the fan 26. In response to the controller12 identifying an error condition for the fan 26, the controller 12 isconfigured to de-activate or limit the fourth control output O4.

Though the first threshold level and the second threshold level arediscussed in reference to the fan 26, each of the compost devices 18 issimilarly configured to have a first threshold level and a secondthreshold level corresponding to an operation or current profile. Eachof the current profiles corresponds to predetermined values or expectedload current values that define normal operating parameters of each ofthe compost devices 18 (e.g., the water supply device 20, the tillermotor 22, the heater 24, the feeder 28, and any other input devicesincorporated in the compost system 10). In response to the load currentbeing less than the first threshold level or greater than the secondthreshold level, the controller 12 is configured to report an errorcondition. The error condition corresponds to a particular compostdevice having a current load draw below or above the first and secondthreshold levels.

In response to the error condition, the controller 12 is furtherconfigured to deactivate the corresponding compost device bydeactivating the control output in communication with the correspondingcompost device. For example, in response the controller 12 identifyingthe load current drawn by the tiller motor 22 exceeds a second currentthreshold level, the controller 12 is configured to deactivate thesecond control output O2. By monitoring the load current drawn by eachof the compost devices 18, the controller 12 is operable to ensureproper operation of the compost devices 18.

In some embodiments, controller 12 is further operable to continue tomonitor and control the compost devices 18 even after one or more of thecompost devices 18 is determined to be in an error condition. Forexample, if a water pump motor of the water supply device 20 isidentified by the controller 12 as being in an error condition, thecontroller 12 is configured to utilize the remaining compost devices 18to attempt to maintain a plurality of desired environmental conditionsof the compost chamber 34. By attempting to maintain the desiredenvironmental conditions, the controller 12 is operable to prevent acompost batch from loss that may occur if all of the compost devices 18are deactivated. Further details of various methods of control andsystems of the compost system 10 are provided in reference to FIGS. 2-5.

Referring again to FIG. 2 a block diagram of the controller 12 is shown.The controller 12 ensures proper compost production by measuring andadjusting the conditions of the refuse material over time. For example,the conditions of the compost may change over time due to thedecomposition of refuse materials added to the compost chamber 34. Theseenvironmental conditions in the compost chamber 34 are tracked by aprocessing unit 62 via the signal inputs I1-I5. By monitoring theenvironmental conditions in the compost chamber 34, the controller 12 isoperable to monitor and regulate the environmental conditions for thecompost during various stages of decomposition to ensure that thecompost is efficiently generated.

Each of the signal inputs I1-I5 and the control outputs O1-O5 are incommunication with the controller 12 via an input output (I/O) module64. The signal inputs I1-I5 may comprise analog or digital inputs of acontrol input module 66 of the I/O module 64. The control outputs O1-O5are output by a control output module 68 of the I/O module 64. Inoperation, the controller 12 is operable to monitor and control theenvironmental conditions of the compost chamber 34 via the control inputmodule 66 and the control output module 68.

The controller 12 utilizes the processing unit 62 to determine theenvironmental conditions in the compost chamber 34 measured by thetransducers S1-S5 via signals received by the signal inputs I1-I5. Thecontroller 12 is configured to adjust the environmental conditions bycontrolling the compost devices 18 via the control outputs O1-O5. Thecontroller 12 comprises one or more processing modules stored in asuitable memory device 69, which may include a read only memory (ROM) 70and a random access memory (RAM) 72. The one or more processing modulesare operable to determine a desired environmental condition for therefuse material according to various stages of decomposition based ondata received from the transducers S1-S5. The processing unit 62 mayaccess the ROM 70 and/or the RAM 72 to determine a control scheme forthe environment of the compost chamber 34 comprising a timing of anoperation (e.g., timing to activate the tiller motor 22) and/or aquantity of materials (e.g., water, coir pellets) to add to the compostchamber 34 based on the processing modules. The processing modules ofthe controller 12 may comprise one or more algorithms, tables, and/orlogical controls configured to monitor and control the maturation of thecompost over time.

As discussed herein, the controller 12 is operable to detect an errorstate of at least one of the compost devices 18 via one or currentsensing circuits. In some embodiments, a current sensing device 16 maycomprise a shunt resistor measuring the current load drawn by each ofthe compost devices 18. The voltage V_(sense) measured across the shuntresistor is may be measured by the controller 12 to determine the loadcurrent and generate the load current value corresponding to each of theoutputs O1-O5.

The controller may utilize at least one H-bridge circuit 76 to control adirection of a DC motor, for example the tiller motor 22. The H-bridgecircuit 76 is controlled by the controller via an H-bridge logic controloutput 80 of the I/O module 64. The H-bridge logic control output 80 isconfigured to control a switching configuration of the H-bridge circuit76 to control a path of electrical current therethrough and consequentlycontrol a direction of a DC motor.

The processing unit 62 receives power from a power supply 86 and alsocomprises a communication interface 88 operable to provide access forservice and/or access to an external storage device and/or any form ofmachine readable media. The compost system 10 includes an interfacepanel and display 90 configured to present information to an operator ofthe compost system 10. The interface panel and display 90 is alsoconfigured to receive inputs to program various operations of thecontroller 12 from a plurality of switches. Each of the plurality ofswitches is in communication with a user input module 92 configured tocommunicate a user selection to the controller 12 from the plurality ofswitches.

The interface panel and display 90 is configured to provide a userinterface for an operator of the compost system 10 to configure thecontroller 12 for a particular operation and communicate graphicalinformation to the operator. The controller 12 further comprises analarm output 94 configured to signal an error state identified in eachof the compost devices 18. The alarm output 94 is in communication witha speaker 96 configured to audibly alert the operator of an errorcondition.

Referring to FIG. 3, a schematic diagram of a control circuit 100configured to selectively activate a current sensing function is shown.As discussed herein, the control output logic 68 is configured by theH-bridge logic control output 80 to provide directional control for DCdevices. The controller 12 is configured to measure the current drawfrom each of the control outputs O1-O5. Each of the control outputsO1-O5 comprises an output circuit 102. In response to the controller 12activating each of the control outputs O1-O5, the controller measuresthe current draw of each of the outputs O1-O5 and generates a currentlevel or load value. The current level or load value may comprise ananalog or digital value or signal that may be utilized by the controller12 to determine if the current draw is within a normal operating range.

In addition a light source 104, for example, a light emitting diode(LED), is activated on the interface panel and display 90. Each lightsource 104 is configured to notify the operator of an active compostdevice 18. Additionally, in response to an active control output O1-O5,a transistor 106 is configured to detect an abnormal current conditionby selectively providing for current sensing for each of the outputsO1-O5. The load current for the active compost device 18 is thenmonitored by the controller 12 via the control input module 66 todetermine if an abnormal current draw is detected from the a compostdevice 18 resulting in a system error condition.

Each of the control outputs O1-O5 may further comprise a driver 110.Each of the drivers 110 is configured to control a compost device 18corresponding to each of the control outputs O1-O5. The drivers 110 maybe configured having different parameters, functions, and architecturecorresponding to a particular compost device 18 (e.g., the tiller motor22, the heater 24, etc.).

The signal inputs I1-I5 are also shown in FIG. 3 demonstrating aschematic view of the system inputs in communication with the controller12 via the control input module 66. Based on the signal inputs andcorresponding signals received from the transducers (S1-S5), thecontroller 12 is configured to selectively activate each of the controloutputs O1-O5 to control each of the compost devices 18. In thisconfiguration, the controller 12 is operable to selectively monitor thecurrent load drawn by each of the compost devices 18 to ensure that thecompost system 10 operates safely and effectively.

Referring to FIG. 4, a flow chart demonstrating a method 120 forcontrolling the compost system 10 is shown. The method 120 begins by thecontroller 12 initializing the compost system 10 to begin a compostingcycle (122). The controller 12 may begin the composting cyclecorresponding to user settings received from an operator of the compostsystem 10 via the interface panel and display 90 (124). During thecomposting cycle, the controller 12 monitors the compost based onscheduled timing to ensure that refuse material in the compost chamber34 achieves the proper conditions throughout the various decompositionstages of the refuse material (126).

The controller 12 is further operable to monitor the signal inputs I1-I5to determine the temperature, humidity level, and an oxygen level of thecompost chamber 34 (128). Based on the signal inputs I1-I5, thecontroller 12 selectively outputs control signals via the controloutputs O1-O5 to regulate the environmental conditions of the compostchamber 34 (130). In response to an active state of any of the controloutputs O1-O5, the controller 12 is configured to monitor the loadcurrent drawn by an active compost device 18 (132). While monitoring theload current drawn by an active compost device 18, the controller 12 maydetermine if the active compost device 18 is drawing current outside ofthe normal operating conditions for the particular compost device 18(134).

As discussed herein, the normal operating conditions for a particularcompost device 18 correspond to the first threshold level and the secondthreshold level. Each of the threshold levels correspond topredetermined values or an expected range of load current values thatdefine normal operating parameters of each of the compost devices 18(e.g., the water supply device 20, the tiller motor 22, the heater 24,the feeder 28, and any other input devices incorporated in the compostsystem 10). In response to the controller 12 determining that the loadcurrent for the active compost device 18 being within the normaloperating parameters (e.g., above a first threshold level and below asecond threshold level), the controller 12 is configured to continue thecompost cycle by progressing to a reference step A.

In response to the load current for the active compost device 18 beingless than the first threshold level or greater than the second thresholdlevel, the controller 12 is configured to deactivate the active compostdevice 18 by deactivating the corresponding output control O1-O5 (136).Hereinafter, the deactivated compost device 18 and correspondingdeactivated output control O1-O5 are referred to as the malfunctioningcompost device and the deactivated output control, respectively. Thecontroller 12 then continues to identify the compost device 18corresponding to the deactivated output control of step 136 and assignan error code in the memory device 69 (138). The error code may identifythe malfunctioning compost device for later service or repair.

Following the identification of an error condition, the controller 12may enter a recovery routine by waiting for a time period T1 andretrying an output operation (140). The controller 12 may retry theoutput operation, depending on load conditions detected by thecontroller 12, N times by reactivating the malfunctioning compost devicevia the previously deactivated output control and monitoring the loadcurrent of the malfunctioning compost device as in step 134. The timeperiod T1 and the number of recovery attempts N as discussed herein maybe any number or value. In an exemplary implementation, the time T1 isapproximately 2 minutes and the number of recovery attempts N is 4.

By retrying the output operation, the controller 12 determines if themalfunctioning compost device has recovered from an error condition(142). If the malfunctioning compost device is determined to haverecovered (e.g., the current draw is within normal operatingparameters), the controller 12 is configured to log an error codeidentifying the malfunctioning compost device in the memory device 69and proceed to a reference step B. If the malfunctioning compost deviceis determined not to have recovered (e.g., the current draw is outsidenormal operating parameters), the controller 12 locks out themalfunctioning compost device and activates the alarm output 94 (144).Following step 144, the controller 12 is configured to progress to areference step C, such that the controller 12 may determine if thecompost cycle has completed the recovery routine. In response to themalfunctioning compost device being unable to recover from the errorcondition, the controller 12 is further operable to execute an errorcontrol routine to isolate the error and protect the composting process.The error control routine is further discussed in greater detail inreference to FIG. 5.

Following each of reference steps A, B, and C, the controller 12determines if the compost cycle is complete (146). If the compost cycleis complete, the controller 12 is configured to move the refuse materialfrom the first bin 36 to the second bin 38 and output a notificationthat the compost is complete on the interface panel and display 90(148). If the compost cycle is not complete, the controller 12 continuesto step 126 to monitor the refuse material throughout the decompositionstages of compost production. The method 120 provides for safe operationof the compost system 10 by monitoring the compost device 18 andalerting an operator in the event of an error condition. The systems andmethods described herein provide various benefits that may preventdamage to the compost system 10 and ensure safe operation.

Referring to FIG. 5, a flow chart demonstrating a method 160 forcontrolling the compost system 10 is shown. The method 160 begins bycompleting method steps 122 through 130 of the method 120 and isdiscussed to provide an exemplary operation of the controller 12 inreference to the tiller motor 22 (162). Based on the scheduled timing ofthe composting cycle and/or the environmental conditions determined bythe signal inputs I1-I5, the controller 12 activates the tiller motor 22to churn and aerate the refuse material in the first bin 36 with thetiller bar 44 (164). To activate the tiller motor 22, the controller 12outputs a control signal via the second output O2 for a time T2 (166).The controller 12 may then control the H-bridge logic 80 for thedirectional control of the tiller motor 22 and measure the current drawfrom control output O2 (168). Any two outputs (O1-O5) can be configuredvia the controller 12, as an H-bridge logic circuit driver 80 to changevoltage polarity for DC devices that require directional operation, suchas the tiller motor 22.

The controller 12 is operable to measure the current supplied by theoutputs (O1-O5) via a current measuring capability and can be configuredto detect when a particular output O1-O5 exceeds or falls below acurrent threshold range. The controller is configured to monitor aregister for the load value corresponding to the current output O2(170). The controller can then analyze the situation by determining ifthe load value for O2 is above or below a current threshold range (172).If one of the load values for the outputs O1-O5 is determined to bewithin the current threshold range for the particular output O1-O5, thecontroller 12 may determine that the compost devices are functioningproperly and continues to determine if the time T2 for the device haselapsed (174). If the value from outputs O1-O5 is determined to be outof range from the current threshold range for the output O1-O5, thecontroller 12 is configured to identify an error condition anddeactivate or limit operation of the device, logging a system error(176).

In response to the error condition, the controller 12 enters a recoveryroutine by waiting for a time period T3 and retrying the outputoperation via the second control output O2 (178). The controller 12 mayretry the output operation N times by reactivating the tiller motor 22via the second control output O2 and monitoring the load current. Thetime periods T2 and T3 as discussed herein may be any time period. In anexemplary implementation, the time T2 may vary based on a particularcomposting system and the environmental conditions detected in thecompost chamber 34. The time T3 may also vary and is approximately 2minutes in some implementations.

By retrying the output operation, the controller 12 determines if themalfunctioning tiller motor 22 has recovered from the error condition(180). If the tiller motor 22 is determined to have recovered (e.g., thecurrent draw is within normal operating parameters), the controller 12is configured to log an error code corresponding to the error identifiedfor the tiller motor 22 in the memory device 69 and proceed to step 174.In step 174, if the time T for the tiller motor 22 to be activated haselapsed, the controller 12 continues to monitor the compost system 10similar to steps 126-134 of the method 120 (182).

In step 180, if the tiller motor 22 is determined not to have recovered(e.g., the current load is outside normal operating parameters), thecontroller 12 locks out or limits the tiller motor 22 via the secondcontrol output O2 and activates the alarm output 94 (184). Thecontroller 12 also displays an error notification on the interface paneland display 90 describing the error condition of the compost system 10(186). For example, the controller 12 may display “Tiller Motor Fault”describing the error identified in the tiller motor 22. In response tothe malfunctioning compost device being unable to recover from the errorcondition, the controller 12 is further operable to execute an errorcontrol routine to isolate the error and protect the composting process.

The error control routine, as discussed herein, provides for varioussteps that allow the controller 12 to continue a composting cycle aftera malfunctioning compost device has been identified and the controller12 has taken the appropriate action to isolate or limit the deviceoperation. As an example, an error control routine is now described inreference to the method 160. Following a locking out or limitingoperation of the tiller motor 22 and the corresponding second controloutput O2, operation of other compost devices 18 may continue to attemptto preserve the compost cycle. By controlling a plurality of operationalcompost devices 18 while at least one of the compost devices 18 is in anerror condition, the controller 12 is operable to preserve thecomposting cycle.

The controller 12 is operable to preserve a composting cycle bymonitoring the signal inputs I1-I5 and controlling the plurality ofoperational compost devices 18 to provide proper conditions for thedecomposition of refuse material. By monitoring the signal inputs I1-I5,the controller 12 may determine that the fan 26 should be activated fora longer period of time than in conditions when the tiller motor 22 isoperational. Similarly, the controller 12 may determine that watersupplied to the compost chamber 34 should be limited due to the errorcondition of the tiller motor 22. By changing the response of thecontroller 12 to the environmental conditions identified by thetransducers S1-S5 based on at least one malfunctioning compost device,the controller 12 is operable to preserve a composting cycle and preventthe loss of the compost being processed in a compost cycle.

The term “computer-readable medium” as used herein refers to any mediumthat participates in providing instructions to the processing unit 62for execution. Such a medium may take many forms, including, but notlimited to, non-volatile media, volatile media, and transmission media.Non-volatile media include, for example, optical or magnetic disks.Volatile media include dynamic memory, such as the RAM 72. Common formsof computer-readable media include, for example, a floppy disk, aflexible disk, a hard disk, a magnetic tape, any other magnetic medium,a CD-ROM, CDRW, DVD, any other optical medium, punch cards, paper tape,optical mark sheets, any other physical medium with patterns of holes orother optically recognizable indicia, a RAM, a PROM, and an EPROM, aFLASH-EPROM, any other memory chip or cartridge, a carrier wave, or anyother medium from which a computer can read.

Various forms of computer-readable media may be involved in providinginstructions to the processing unit 62 for execution. For example, theinstructions for carrying out at least part of the present disclosuremay be accessed from the ROM 70, the RAM 72, and the communicationinterface 88, which may further be in communication with a storagedevice. The processing unit 62 is configured to retrieve and execute theinstructions based on data received from the control input module 66,the communication interface 88, the memory device 69, and variousdevices that may be in communication with the controller 12. Theinstructions received by the RAM 72 can optionally be stored on astorage device either before or after execution by a processor.

It will be understood that any described processes or steps withindescribed processes may be combined with other disclosed processes orsteps to form structures within the scope of the present device. Theexemplary structures and processes disclosed herein are for illustrativepurposes and are not to be construed as limiting.

It is also to be understood that variations and modifications can bemade on the aforementioned structures and methods without departing fromthe concepts of the present device, and further it is to be understoodthat such concepts are intended to be covered by the following claimsunless these claims by their language expressly state otherwise.

The above description is considered that of the illustrated embodimentsonly. Modifications of the device will occur to those skilled in the artand to those who make or use the device. Therefore, it is understoodthat the embodiments shown in the drawings and described above is merelyfor illustrative purposes and not intended to limit the scope of thedevice, which is defined by the following claims.

What is claimed is:
 1. A controller for a compost system comprising: aplurality of control outputs in communication with a plurality ofcompost devices, wherein the control outputs are configured to identifyan error condition of at least one of the plurality of compost devices,wherein the controller is configured to: control a first compost deviceof the plurality of compost devices configured to control a firstenvironmental condition of a compost chamber; control a second compostdevice of the plurality of compost devices configured to control asecond environmental condition of the compost chamber; identify theerror condition of the first compost device; deactivate the firstcompost device in response to the error condition during a compostcycle; and control the second compost device in response to the firstcompost device being deactivated, wherein the second compost device iscontrolled preserving the compost cycle by compensating for the errorcondition in the first compost device.
 2. The controller according toclaim 1, wherein the plurality of compost devices comprise at least oneof a water pump, an electric motor, and a heater.
 3. The controlleraccording to claim 1, wherein the controller further comprises: ameasurement circuit operable to selectively measure a load current ofeach of the plurality of control outputs.
 4. The controller according toclaim 1, further comprising: a plurality of signal inputs configured toreceive signals identifying the environmental conditions of the compostchamber.
 5. The controller according to claim 4, wherein theenvironmental conditions comprise one or more of an oxygen level, atemperature, and a humidity level in the compost chamber.
 6. Thecontroller according to claim 1, wherein the first compost devicecomprises a tiller motor configured to actuate a tiller disposed in thecompost chamber.
 7. The controller according to claim 1, wherein thesecond compost device comprises a fan motor in connection with a fan,wherein the fan is configured to circulate air in the compost chamber.8. The controller according to claim 7, wherein the controller isfurther configured to: control the second output adjusting an operationtime of the fan preserving the compost cycle in response to thedeactivation of the first compost device.
 9. The controller according toclaim 1, wherein the second compost device comprises a water supplyconfigured to deliver water to the compost chamber.
 10. The controlleraccording to claim 9, wherein the controller is further configured tocontrol the second output adjusting a volume of water supplied to thecompost chamber by the water supply preserving a compost cycle inresponse to the deactivation of the first control output.
 11. Thecontroller according to claim 1, wherein the first compost device isconfigured to process a compost mixing process and the second compostdevice is configured to circulate air in the compost chamber.
 12. Amethod for controlling a compost system comprising: selectivelyactuating a first compost device of the compost system, wherein thefirst compost device is configured to control a first environmentalcondition of a compost chamber; selectively actuating a second compostdevice of the compost system, wherein the second compost device isconfigured to control a second environmental condition of the compostchamber; monitoring the operation of the first compost device; detectingan error condition in the first compost device; limiting operation ofthe first compost device in response to the error condition; andcontrolling the second compost device in response to the limitedoperation of the first compost device, wherein the second compost deviceis controlled preserving the compost cycle by compensating for the errorcondition in the first compost device.
 13. The method according to claim12, further comprising: selectively measuring the load current of eachof the plurality of compost devices to identify the error condition. 14.The method according to claim 12, further comprising: receiving at leastone signal from a transducer configured to detect at least one of theenvironmental conditions of the compost chamber.
 15. The methodaccording to claim 14, wherein the environmental conditions comprise atleast one of an oxygen level, a temperature, and a humidity level in thecompost chamber.
 16. The method according to claim 12, wherein the firstcompost device is configured to till material in the compost chamber.17. The method according to claim 12, wherein the second compost deviceis configured to circulate air in the compost chamber.
 18. The methodaccording to claim 12, wherein controlling the second compost device inresponse to the limited operation of the first compost device comprisesadjusting an operation time of the second compost in response to thelimited operation of the first compost device.
 19. The method accordingto claim 18, wherein adjusting the operation time of the second compostdevice comprises increasing an operating time of a fan preserving thecompost cycle in response to the limited operation of the first compostdevice.
 20. The method according to claim 18, wherein adjusting theoperation time of the second compost device comprises decreasing avolume of water supplied to the compost chamber preserving the compostcycle in response to the limited operation of the first compost device.